EE Benchmarking for Cement Industrys

2ND WORKSHOP ON “BEST PRACTICES IN ENERGY EFFICIENCY IN CEMENT SECTOR” UNDER KEP INITIATIVE

ENERGY EFFICIENCY BENCHMARKING FOR CEMENT INDUSTRYIMPROVEMENT OPPORTUNITIES 7th & 8th July’16, at My Home Industries Pvt. Ltd., Mellacheruvu

1

SEC reduction – CII Experiences Electrical SEC reduction range Reduction in 2014-15 (%):

Average reduction % (last 3 yrs): Average yearly reduction % (for 40+ cement plants)

2

Thermal SEC reduction range

0.00 – 6.581 Average – 2-3%

0.00-4.40 Average – 1-1.5%

0.00-8.712

0.00-2.55

2.04

0.831

© Confederation of Indian Industry

PAT GTG Energy Reduction  Escerts gain (PAT cycle -1)

– 50,000 +  Main factors for achieving target 

Improvement in clinker factor 

From 0.741 to 0.640 in PPC 



Flyash % : From 23% to 32.5 %

Reduction in energy consumption by various energy conservation measures  Clinkerization :

55.4 kWh/Mt clk to 52.3 kWh/MT clk  Cement grinding: 27.7 kWh/MT to 26.1 kWh/MT cement  Thermal: 714 kcal/kg clk to 705 kcal/kg clk  CPP heat rate: 3169 kcal/kWh to 3036 kcal/kWh  AFR Slide 3

utilization Increased by 4% + © Confederation of Indian Industry

Approach #1 Energy Benchmarking

4


Energy Benchmarking - Objective 



   

Awareness and identification of Best Available Technologies & Best Practices Assess our own energy performance Comparison with peers Identify gaps and possible solutions Formulate the strategies Monitor key parameters to maintain and sustain benefits 5


CII EE Benchmarking Manual contains… 1. Performance of Top 10 Plants : Section wise & Technology Wise 2. Analysis and Potential areas of improvement with cost economics 3. Case studies to bridge the gap 4. 50 Energy Indicators – Islands of Excellence 5. 325 Best Practices 6. 139 Monitoring Parameters to achieve EE Benchmarking is Dynamic : It is highly possible that few plants may operate energy levels lower than best values mentioned in this manual !!!!! 6


Crusher SEC : kW / MT Material

Single Stage Crusher

Double Stage Crusher 1.13

1.20 1.00 0.70

0.80

0.73

0.84

0.60 0.40 0.20 0.00 Plant 1 Plant 2 Plant 3 Top 10

7

1.40 1.20 1.00 0.80 0.60 0.40 0.20 0.00

1.28 0.91

0.94

0.65

Plant 1 Plant 2 Plant 3 Top 6


Raw Mill SEC : kW / MT Material

8


Pyro Section SEC : kW / MT Material

5 Stage Preheater 30.00 25.00

21.80

20.00

16.28

23.55

18.30

15.00 10.00 Plant 1 Plant 2 Plant 3 Top 10

10


Thermal SEC: kcal/ kg Clinker

11


Cement Grinding SEC : kW / MT Material

12


Packing SEC : kW / MT Material

13


Electrical Energy – Upto Clinkerisation SEC : kW / MT Clinker

14


Electrical Energy – Overall SEC : kW / MT cement

15


Overall SEC kW / MT Cement- CII Energy Award 2014-15

16


Best Number possible with BAT- kW / MT OPC SL No

Section

kW / Material

kW / MT Cement

5 Stage PH 1

Crusher

2

Raw Mill - VRM

3

Coal Mill – VRM

4

Pyro

0.7 13.3 23.9 16.28

Up to Pyro

1.03 18.95 2.97 15.47

kW / Material

kW / MT Cement

6 Stage PH 0.7 13.3 23.9 18.7

1.03 18.95 2.97 16.25

38.42

5

Cement Mill VRM

21.00

21.00

21.00

39.20 21.00

6

Packing

0.65

0.65

0.65

0.65

7

Misc.

2.00

2.00

2.00

2.00

Overall 17

62.07 © Confederation of Indian Industry

62.85

Islands of Excellence  



  





PH fan lowest SEC – 3.88 kWh/MT clinker Lowest pressure drop in PH : 375 mmWc for 5 stage and 470 mmWc for 6 stage Fine coal phase density : 5.5 kg coal / kg air Lowest RM Cyclone pressure drop : 50 mmwc Lowest false air across RM circuit : 11% Lowest compressed air generation pressure for plant air requirement : 4.5 bar Lowest CA fan power : 1.2 kWh/Mt cement Lowest APC in CPP : 5.36% 18


Approach #2 Innovative Projects to reduce SEC


CASE STUDY: Installation of High Efficiency Separators Seal Gap Features: Air is blown in this gap to avoid any bypass of coarse material to get into the fine product


CASE STUDY: Improving Separator Efficiency


CASE STUDY: Improving Separator Efficiency 

Benefits Achieved:  Bypass is reduced from 28 % to 7 %.  Production increase by 14 %  Specific energy reduced by 13.8 %  Blaine reduced from 3800 cm2/gm to 3600 cm2/gm  Same early and final strength achieved with reduced blaine © Confederation of Indian Industry

Improving VRM classifier performance

Annular Gap

between Dynamic seal and rotor to be close.

Additional Air – “Sealing Air” to be provided by a radial fan with a static pressure of 40 to 50 mbar to stop/direct passive particles © Confederation of Indian Industry

Saving & Benefits Without seal air Sep.speed (RPM)

Fan power (KW)

Main motor load (KW)

Grinding pressure (mbar)

Vibration

Feed (TPH)

Residue (212 µ)

80

834

1240-1260

120

3.8-4.2

170

4.6%

With seal air Sep.speed (RPM)

80

Fan power (KW)

820

Main motor load (KW)

Grinding pressure (mbar)

Vibration

1230-1250

120

3.8-4.2

Feed (TPH)

175

Residue (212 µ)

3.6%

Through 4th Generation Classifier • Benefits in quality of raw mill product • Power saving in VRM main fan & main drive • Increase output of VRM Through study we get that power saving of 30 kW/Hr & Increase In production by 5 TPH

Total Annual Savings – RS. 221 Lakhs © Confederation of Indian Industry

Cooler hot gas recirculation 

Recirculation of cooler stack hot air at 110130oC inside cooler  

Increase in steam generation Increase in power generation


Cooler hot gas recirculation- J K Lakshmi Cement


Approach #3 Performance Improvement in CPPs

27


CPP – APC % & PLF

28


APC % - Captive Power Plant Scenario Sl. No

Operating Capacity, MW

APC %

Plant A Plant B Plant C Plant D Plant E Plant F Plant G Plant H Plant I Plant J

06 15 15 15 18 25 25 27 30 33

13.5 9.82 7.73 7.57 7.80 8.15 10.95 7.69 6.96 11.0

Slide 29


Estimated potential available in Indian CPP  Captive power plants  APC

% ranges : 5 – 12.5%

 Large Bandwidth

 Example:  Installed

capacity :34444.12 MW  Operating Capacity : 27555.3 MW @ 80% PLF  APC power : 2342.2 MW @ 8.5% APC (average)  At least 1% reduction in APC%  Huge

increase in the Net Power Generation

 Approx. 275 MW

Slide 30


Typical APC % Breakup

Slide 31


APC% Benchmarking - AFBC boilers Sl. Auxiliary Name Specific Power No. Consumption, kW/MW 1 Fans (PA, SA, ID & ACC fans) 17.9 2 Pumps (BFP, CEP, & ACWP) 24.6 3 BOP (WTP, CHP, ESP, Lighting, AC, CHP, Compressors & Misc.) 11.1 Total 53.6 (APC – 5.36%) Slide 32


APC% Benchmarking - CFBC boilers Sl. Auxiliary Name No. 1 Fans (PA, SA, ID & ACC fans) 2 Pumps (BFP, CEP, & ACWP) 3 BOP (WTP, CHP, ESP, Lighting, AC, CHP, Compressors & Misc.) Total Slide 33

Specific Power Consumption, kW/MW 29.79 25.74

9.83 65.36 (APC – 6.53%)


Approach #4 Innovative Ideas from Other Sectors

35


Shift-wise Energy Monitoring …

36


Detailed monitoring of minor areas …

37


Resource Allocation for EE …

APPROVED CAPEX

PLANNED INITIATIVES OTHER CAPEX

UN-PLANNED INITIATIVES/ KAIZENS

OPEN SCHEMES FLEXIBLE SCHEMES SUBSTITUTION SCHEMES © Confederation of Indian Industry

Campaings on EE …


Approach #5 Major Levers to achieve PAT Targets

40


Levers towards PAT targets 1. 2. 3. 4.

Increasing additives in blended cement Waste Heat Recovery Alternate Fuel Utilization On-site Renewable Energy options

41


To sum up … Several opportunities to improve SEC  Successful examples within this sector and beyond  Newer innovative technologies also finding acceptance & adoption  Energy managers play a vital role in units’ performancee 

42


Thank you! Vaibhav Girdhar Counsellor Confederation of Indian Industry CII - Godrej Green Business Centre, India Dir: +91 40 4418 5216 E-mail: [email protected] www.greenbusinesscentre.com / www.cii.in © Confederation of Indian Industry

EE Benchmarking for Cement Industrys

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